ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500 Electromagnetic Flowmeter

Transcription

1 SIL-Safety Instructions SM/FEX300/FEX500/SIL-EN Rev. C ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500 Electromagnetic Flowmeter Information about functional safety Measurement made easy

2 Change from one to two columns Short product description Electromagnetic Flowmeter for flow measurement of liquid, pulpy or pasty measurement media with electrical conductivity. Further information Additional documentation on ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500 is available to download free of charge at FEP300 FEP500 FEH300 FEH500 Manufacturer ABB Automation Products GmbH Measurement & Analytics Dransfelder Str Göttingen Germany Tel: Fax: Customer service center Tel.: Mail: automation.service@de.abb.com 2 SM/FEX300/FEX500/SIL-EN Rev. C ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500

3 Change from two to one column Contents 1 Acronyms and abbreviations Standards and definitions of terms Standard IEC (2010), Part 1 and Dangerous failure Safety-related system Safety function Other applicable documents and papers Determine the Safety Integrity Level (SIL) The Flowmeter as part of the safety function system Device specific data related to functional safety Prerequisites operating the device functional safety compliant Setup Analog output Locking / Unlocking the configuration level Hardware write protection Configuration of the flowmeter transmitter Proof Test Calibration On-site test, performed by ABB service personnel ScanMaster Verification Repair SIL 2 certificate ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500 SM/FEX300/FEX500/SIL-EN Rev. C 3

4 Change from one to two columns 1 Acronyms and abbreviations Abbreviation Designation Description HFT Hardware Fault Tolerance Hardware fault tolerance of the unit. Ability of a functional unit (hardware) to continue to perform a required function when faults or errors are prevailing. MTBF Mean Time Between Failures Mean time between failures. MTTR Mean Time To Restoration Mean time between the occurrence of an error in a unit or in a system and its repair. PFD Probability of Dangerous Failure on Demand Probability of hazardous failures for a safety function on demand. PFD AVG Average Probability of Dangerous Failure on Average probability of hazardous failures for a safety function on demand. Demand SIL Safety Integrity Level The international standard IEC defines four discrete Safety Integrity Levels (SIL 1 to SIL 4). Each level corresponds to a range of probability for the failure of a safety function. The higher the Safety Integrity Level of the safety-related systems, the lower the probability that they will not perform the required safety function. Low Demand Mode Low Demand Mode of operation Measurement type with low request rate. Measurement type for which the request rate for the safety-related system is not more than once a year and not greater than twice the frequency of the retest. DCS Distributed Control System Control system used in industrial applications to monitor and control decentralized units. HMI Human Machine Interface In this case, the HMI is a combined module consisting of an LCD display with or without a local keyboard. DTM Device Type Manager A DTM is a software module that supports specific functions for accessing device parameters, the setup and the operation of devices, and diagnostics. The DTM is not executable software. It requires an FDT container program in order to be activated. LRV Device Configuration Lower Range Value of the measurement range. URV Device Configuration Upper Range Value of the measurement range. DC Diagnostic Coverage Fraction of dangerous failures covered by cyclical diagnosis functions on runtime. Multidrop Multidrop Mode In Multidrop Mode, up to 15 field devices are connected in parallel to a single wire pair. The analog current signal simply serves to supply power to the devices in two-wire technology with a fixed current of 4 ma. 4 SM/FEX300/FEX500/SIL-EN Rev. C ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500

5 2 Standards and definitions of terms 2.1 Standard IEC (2010), Part 1 and 2 English Functional safety of electrical / electronic / programmable electronic safety-related systems (Target group: Manufacturers and Suppliers of Devices). German Funktionale Sicherheit sicherheitsbezogener elektrischer / elektronischer / programmierbarer elektronischer Systeme (Zielgruppe: Hersteller und Lieferanten von Geräten). 2.2 Dangerous failure A failure that has the potential to place the safety-related system in a dangerous state or render the system inoperative. 2.3 Safety-related system A safety-related system performs the safety functions that are required to achieve or maintain a safe condition, e.g., in a plant. Example: pressure meter, logics unit (e.g., alarm signalling unit) and valve form a safety-related system. 3 Other applicable documents and papers The following documentation must be available for the flowmeter. These documents include details about functional specifications of the analog output and how to operate and configure the device. Document name CI/FEX300/FEX500 OI/FEX300/FEX500 Document type Commissioning Instruction Operating Instruction For devices in explosion-proof design, the Safetey Instructions must also be observed. Document name SM/FEX300/FEX500 Document type Safety Instructions 2.4 Safety function A specified function that is performed by a safety-related system with the goal, under consideration of a defined hazardous incident, of achieving or maintaining a safe condition for the plant. Example: limit pressure monitoring ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500 SM/FEX300/FEX500/SIL-EN Rev. C 5

6 4 Determine the Safety Integrity Level (SIL) The achievable Safety Integrity Level for a device certificated according EN route 2S and 2H is determined by the following safety-related parameters: Average probability of hazardous failures for a safety function on demand (PFD AVG ) Hardware Fault Tolerance (HFT) Table below shows the achievable Safety Integrity Level (SIL) based on the Average Probability of Failure on Demand (PFD AVG ) for the complete safety function system consisting of the Flowmeter, the Logics Unit and the Actuator. Safety Integrity Level (SIL) PFD AVG (low demand mode) < < < < 10-1 Table below shows the achievable Safety Integrity Level (SIL) for the complete safety-related system for type B systems depending on the Hardware Fault Tolerance (HFT). Type B systems are, for example, sensors with complex components such as microprocessors (see IEC 61508, Part 2). Hardware Fault Tolerance (HFT) SIL 1 SIL 3 SIL 4 SIL 2 (low demand mode) SIL 2 (high demand mode / continuous mode) NOTICE ProcessMaster and HygienicMaster flowmeter fulfill HFT = 0 and are applicable for safety-related systems as per table above. In low demand mode the demand rate for the safety-related system is not more than once a year and not greater than double the frequency of the periodic test. 6 SM/FEX300/FEX500/SIL-EN Rev. C ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500

7 5 The Flowmeter as part of the safety function system Fig. 1: Safety function (e.g. min / max flowrate monitoring) with flowmeter as a sub-system a ProcessMaster or HygienicMaster b Notebook with configuration Tool such as SMART VISION c FSK-Modem d Handheld terminal e Automation System, Logic-Unit, PLC, alarm signalling unit, etc. f Actuator The Flowmeter transmitter generates an analog signal ( ma) proportional to the flowrate. The analog signal is fed to a downstream logics unit such as a PLC or an alarm signalling unit, and is monitored for exceeding a specified maximum or minimum value. NOTICE The safety-related signal is the ma analog output signal of the flowmeter transmitter. All safety functions refer exclusively to this analog output (terminals 31 / 32) Device specific data related to functional safety Term Value DeviceType ProcessMaster FEP300, FEP500, HygienicMaster FEH300, FEH500 Firmware Level from to Hardware Level Electronics compartment Part number D674A903U01 Rev. 05 to 13 Par tnumber D674A904U01 Rev. 05 to 13 Part number D674A905U01 Rev. 05 to 13 Part number D674A906U01 Rev. 05 to 13 Type of Assessment Proven in Use Assessment according IEC route 2S Hardware Fault Architecture Route 2H according to IEC Tolerance SIL capability SIL2 (Low demand mode) HFT 0 Component Type B Failure Rates SIL Detector OFF ON DC 71.1 % 82.6 % PFD AVG after 10 years with Proof Test Interval 2,65E-03 1,51E-03 of 1 year and Proof Test Coverage of 90 % (valid for FEX311, FEX511, FEX315, FEX515, FEX325, FEX525) PFD AVG after 6 years with Proof Test Interval of 2,09E-03 1,20E-03 1 year and Proof Test Coverage of 90 % (valid for FEX321, FEX521) λ SD 0 FIT 0 FIT λ SU 943 FIT 943 FIT λ DD 937 FIT 1070 FIT λ DU 317 FIT 181 FIT NOTICE The configuration menu of the device includes a parameter called SIL Detector. To assure PFD value as per table above, the Detector has to be set accordingly. ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500 SM/FEX300/FEX500/SIL-EN Rev. C 7

8 NOTICE The listed failure rates λ SD, λ SU, λ DD and λ DU depend on the meter design (standard or high temperature design). The listed failure rates λ SD, λ SU, λ DD and λ DU are valid for ambient temperatures up to 45 C. For higher ambient temperatures up to 60 C, the failure rates and the PFD AVG must be multiplied with a factor of 2.5. See diagram below C 45 C 25 C Prerequisites operating the device functional safety compliant The analog signal of the transmitter can be considered to be safe after 30 minutes (warm up time). A dangerous error is an error during which the output analog output of the transmitter no longer responds to the input signal or deviates by more than 2 % from the maximum flowrange Q max DN. For Q max DN see device nameplate or refer to instruction manual. The maximum reaction time of the device on error is less than 3 hours. The response time of the current output depends on the parameterization (Noise Filter settings and Damping) and is less than 5 Minutes. 90 C 130 C 2 G11926 Fig. 2: Standard temperature design 1 Ambient temperature 2 Fluid temperature 3 Failure rates and PFD AVG to be multiplied with a factor of Failure rates and PFD AVG as per table 1 60 C 3 45 C 4 25 C 140 C 180 C 2 G11927 Fig. 3: High temperature design 1 Ambient temperature 2 Fluid temperature 3 Failure rates and PFD AVG to be multiplied with a factor of Failure rates and PFD AVG as per table 8 SM/FEX300/FEX500/SIL-EN Rev. C ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500

9 Change from two to one column 6 Setup 6.1 Analog output The status of this analog output (4 20 ma output) during alarm conditions, can be configured either to go to a high alarm level or to a low alarm level. (See instruction manual). For high alarm level, a range from ma can be assigned to the analog output. For low alarm level, a range from ma can be assigned to the analog output. NOTICE The safety function of the automation system must be able to detect errors that result in high alarm level as well as those that result in low alarm level. The analog output signal of the transmitter can be configured as active mode or as passive mode. With the analog output configured passive mode, the external supply power of the 20mA loop must be capable to provide the required voltage level even in case of a high alarm level. NOTICE After completion of the parameter configuration, the safety function has to be checked. The transmitter software menu allows for simulation of the analog output. See Instruction manual. Behavior during operation and failure is described in the operating instructions. 6.2 Locking / Unlocking the configuration level WARNING Unauthorized changes of the parameter settings may affect the safety function. This device can be configured through the local Keypad or using HART communication. During configuration and in case of simulation and driving the device in HART Multidrop Mode, the device is not safety compliant. Once configuration is completed, the device must be protected against unauthorized access. Refer to Instruction manual set hardware write switch to ensure the keypad is locked and write protection through HART is enabled too. With the hardware write protection switched to ON, try to alter a parameter to make sure the write protection mechanism is enabled properly. To lock the device access menu Device Setup / Access Control and set the password of the corresponding log in level. Menu / parameter Value range Description Device Setup /...Access Control Standard Password Alphanumeric Enter the password for the "Standard" access level. Advanced Password Alphanumeric Enter the password for the "Advanced" access level. Read Only Switch Display only (ON / OFF) Display the setting of the configuration of the Read Only switch (BR902 - hardware write protection) ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500 SM/FEX300/FEX500/SIL-EN Rev. C 9

10 6.2.1 Hardware write protection In addition to the software password protection, it is possible to enable a hardware write protection. 2 A 1 B 2 A 1 B Fig. 4: Jumper for hardware write protection A Integral mount design B Remote mount design a Housing cover b Jumper (BR902) for hardware write protection G Switch off power supply. 2. Open the housing cover. 3. Remove the mounting screws for the transmitter electronics unit. 4. Pull out the transmitter electronics unit. 5. Set jumpers on backplane in accordance with the following table. Jumper Number Function BR902 Read only Hardware write protection active 6. Reinstall the transmitter electronic unit in reverse order. 10 SM/FEX300/FEX500/SIL-EN Rev. C ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500

11 6.3 Configuration of the flowmeter transmitter Note Some parameter settings may affect the safety function. Changing these parameters, the safety function has to be checked again. Refer to Commissioning Instruction (CI/FEX300/FEX500) and Operating Instruction (OI/FEX300/FEX500) for Settings and Installation Instructions. Menu / parameter Description Action Diagnostics /...Diagnosis Control / Sil Detection Sil Detection To assure PFD value as per table in chapter 2.1, the Detector has to be set accordingly. Check Safety Function. Easy Setup Q [units] Select the engineering unit for flowrate indication in the display. Qmax Select the flow range for forward and reverse flow. Default setting: 1 x QmaxDN. Damping Select the damping. The setting relates to 1 Τ (Tau). The damping affects the analog output response time. Default setting: 1 second. Iout at Alarm Status of the analog output during error conditions can be configured either to go to a high alarm level or to a low alarm level. (See instruction manual). Default setting: High. Low Alarm Value Analog output Low alarm level. A range from 3,5 to 3,6mA can be assigned to the analog output. Default setting: 3.5 ma. High Alarm Value Analog output High alarm level. A range from 21 to 23mA can be assigned to the analog output. Default setting: 21.8 ma. System Zero Manual adjustment of the system zero. Cable length Enter the signal cable length between the transmitter and the flowmeter sensor. For devices with a compact design (FEP311, FEH311, FEP315, FEH315) 0.01 m must be entered. Device Setup /...Sensor Qmax2 See Qmax. Range Mode Manual switchover between flow range Qmax and Qmax2. ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500 SM/FEX300/FEX500/SIL-EN Rev. C 11

12 Menu / parameter Description Action Device Setup /...Transmitter /...Units Custom Vol. Type Select whether the user-defined flow unit is displayed as a mass flow (with density) or volume flow (without density). Check Safety Function. When a mass flow unit is selected, the corresponding density must be set. Custom Vol. Factor Enter the factor for a user-defined flow unit. The factor relates to the flow per liter. Check Safety Function. Device Setup /...Transmitter Density To show the flowrate in massflow units a fixed density must be configured to convert the volume flowrate into mass flowrate. Device Setup /...Transmitter /...Low Flow Cut Off Flow Cut Off Level Threshold for low flowrate monitoring. Check Safety Function. If the flowrate is below threshold, the flow is not measured. The current output is set to zero. Hysteresis Set the hysteresis for the low flow cut off. Check Safety Function. Device Setup /...Transmitter /...Operating Mode Meter Mode Measuring direction for the flowmeter. Forward only : The device measures only forward flow direction. Forward and Reverse : The device measures both directions. Check Safety Function. Device Setup /...Transmitter / Noise Reduction Noise Reduction Enables noise filtering. Filtering increases the response time of the SIL relevant ma output. Input/Output /...Current Output Iout at EP Alarm Iout at Flow >103% Iout Mode Status of the analog output during empty pipe condition. Off: Error is not output at the current output. Q = 0 %: The current output assumes the value for No flow. High Alarm: The current output assumes the value for High Alarm. Low Alarm: The current output assumes the value for Low Alarm. Default setting: Off. Status of the analog output when flowrate exceededs 103 % of the flow range end value set. Off: Error is not output at the current output. High Alarm: The current output assumes the value for High Alarm. Low Alarm: The current output assumes the value for Low Alarm. Default setting: Off. Select the operating mode for the current output ma - 4 ma = No flow - 20 ma = Maximum flow ma - 4 ma = Maximum reverse flow - 12 ma = No flow - 20 ma = Maximum forward flow 12 SM/FEX300/FEX500/SIL-EN Rev. C ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500

13 Change from one to two columns Menu / parameter Description Action Process Alarm /...Group Masking Maintenance Required Alarm messages are divided into 3 groups. Masking is not allowed for Function Check Out of Specification Maintenance, Function Check and Out of Spec. Masking of a group results in no error message any longer for errors belonging to this group. parameter setting for a Functional Safety application. Parameter has to be switched to OFF. Process Alarm /...Individual Masking Min Flowrate Alarm Individual alarm messages can also be masked. Max Flowrate Alarm These alarms are not included in the masking of a group such a Maintenance. Flow >103% Masking of an individual alarm results in no error message any longer for this Com Controller Alarm alarm. Empty Pipe Detector completed Process Alarm / Alarm Simulation Simulation Mode Manual simulation of measured values. The output values correspond to the simulated flowrate entered. The Configuration information is displayed in the lower line of the display. Restore the Simulation mode to Off once The values in the Value range column can be simulated. Make sure Simulation mode is switched to Off once Diagnostics /...Diagnosis Control /...Empty Pipe Detector Manual Adjust EP Manual adjustment of the Empty Pipe Detector function. Flow Cut Off Level Threshold of the empty pipe detection. Diagnostics /...Diagnosis Control /...Sensor Measurements Coil R. Max Alarm Set the maximum limit value for the coil resistance. Exceeding this limit results in an alarm. Coil R. Min Alarm Set the minimum limit value for the coil resistance. Exceeding this limit results in an alarm. ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500 SM/FEX300/FEX500/SIL-EN Rev. C 13

14 Change from two to one column 7 Proof Test In accordance with IEC61508, the safety function of the measuring device must be checked at appropriate time intervals. The operator must determine the checking interval and take this into account when determining the probability of failure PFDavg of the flowmeter. The test must be carried out in such a way that it verifies correct operation of the device. Testing the device can be performed in the following steps: 7.1 Calibration Calibrating the device in a certified calibration rig checking the analog output safety function results in a > 98 % diagnostic coverage detecting undetected failures. 7.2 On-site test, performed by ABB service personnel An on-site test, performed by ABB service personnel results in a > 90 % diagnostic coverage detecting undetected failures. 8 Repair To ensure the safety related function, repairs have to be performed by ABB. Replacing modular components by original ABB spare parts is permitted if personnel was trained by ABB for this purpose. The "Declaration of contamination and cleaning" must be enclosed when returning the defective device. Refer to instruction manual for further details. Adress: ABB Automation Products GmbH Measurement & Analytics Dransfelder Str Goettingen Germany Tel: Fax: ScanMaster Verification Performing a ScanMaster Verification results in a > 50 % diagnostic coverage detecting undetected failures. If the test is not passed, the device may no longer be used as part of a protective system. The influence of systematic faults on the safety function are not covered by the test and must be examined separately. Systematic faults can be caused, for example, by medium properties, operating conditions, build-up or corrosion. 14 SM/FEX300/FEX500/SIL-EN Rev. C ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500

15 9 SIL 2 certificate ProcessMaster FEP300, FEP500 HygienicMaster FEH300, FEH500 SM/FEX300/FEX500/SIL-EN Rev. C 15

16 Notizen Contact us ABB Limited Measurement & Analytics Howard Road, St. Neots Cambridgeshire, PE19 8EU UK Tel: +44 (0) Fax: +44 (0) Mail: ABB Inc. Measurement & Analytics 125 E. County Line Road Warminster, PA USA Tel: Fax: Note We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB. Copyright 2017 ABB All rights reserved 3KXF231304R4801 SM/FEX300/FEX500/SIL-EN Rev. C ABB Automation Products GmbH Measurement & Analytics Dransfelder Str Goettingen Germany Tel: Fax: Mail: vertrieb.messtechnikprodukte@de.abb.com ABB Engineering (Shanghai) Ltd. Measurement & Analytics No. 4528, Kangxin Highway, Pudong New District Shanghai, , P.R. China Tel: +86(0) Fax: +86(0) Mail: china.instrumentation@cn.abb.com